Académique Documents
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SERVICE MANUAL
GARDA
Models:
M90F.24S
M90F.28S
M90F.32S
M90F.24SR
M90F.28SR
47--970--19
47--970--20
47--970--22
41--970--10
41--970--11
Biasi UK Ltd
Newman Park, Western Way
Wednesbury, WS10 7BJ
Sales Tel No: 0121 506 1340
Sales Fax No: 0121 506 1360
Service Tel No: 0121 506 1350
Service Fax No: 0121 506 1370
www.biasi.co.uk
Table of contents
1
1.1
1.2
Overall information . . . . . . . . . . . . . . . . . .
Overall View . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic diagram . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3
3
3
4
4
4
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.2
3.3
3.4
Wiring diagram
M90F.24S M90F.28S, M90F.32S . . . . . . . . 5
Wiring diagram M90F.24SR, M90F.28SR
7
Functional flow diagrams . . . . . . . . . . . . . . 9
Circuit voltages . . . . . . . . . . . . . . . . . . . . . . 10
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . 12
5
5.1
5.2
5.3
6
6.1
6.2
7
7.1
7.2
7.3
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8.1
8.2
8.3
8.4
14
14
14
14
10.2
10.3
10.4
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ignition and control sequence . . . . . . . . . . 26
11
11.1
11.2
11.3
11.4
11.5
11.6
27
27
27
27
28
28
28
12
12.1
12.2
12.3
29
29
29
29
13
13.1
13.2
13.3
13.4
30
31
31
31
31
31
14.6
16
16
16
16
15
15.1
15.2
15.3
Temperature probe . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
33
33
17
17
17
17
16
16.1
16.2
By -- pass valve . . . . . . . . . . . . . . . . . . . . . . 34
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
17
17.5
18
18.1
18.2
18.3
37
37
37
37
19
19.1
19.2
19.3
Safety thermostat . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
39
20
18
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection and adjustment devices . . . . . .
Checking the temperature . . . . . . . . . . . . .
Operation/Service lamps . . . . . . . . . . . . . .
Dip---switch selectors . . . . . . . . . . . . . . . . .
Setting jumpers . . . . . . . . . . . . . . . . . . . . . .
Ignition gas pressure adjustment . . . . . . .
Max c.h. power adjustment . . . . . . . . . . . .
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the electronic control p.c.b . .
Thermal control in the mode . . . . . .
9.12
10
10.1
19
19
19
20
21
22
22
22
22
22
24
mode . . . . . . 24
14
14.1
14.2
14.3
14.4
14.5
30
30
30
30
17.1
17.2
17.3
17.4
31
32
35
35
35
36
36
36
Overall information
1.1
Overall View
Air pressure
switch
Fan
Main heat
exchanger
Safety
thermostat
Burner
Expansion
vessel
Combustion
chamber
Ignition
electrodes
Detection
electrode
Diverter valve
Automatic
air release
valve
Main circuit
flow switch
D.h.w. temp.
probe
Pump
Gas valve
D.h.w
flow switch
Control
panel
1.2
Hydraulic diagram
C.h.
water return
D.h.w.
heat exchanger
C.h.
water flow
D.h.w.
inlet
D.h.w
outlet
2.1
Nomenclature
2
6
Fig. 2
D
5
Fig. 1
Front panel
Service panel
C
Fig. 3 --- bottom view of the boiler
2.3
2.2
Body panels
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
For the most part of the check and maintenance operations it is necessary to remove one or more panels of
the case.
The side panels can be removed only after the removal
of the front panel.
To remove the front panel remove screws A (Fig. 2), lift
the panel and remove it.
Control panel
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Move the lower part of the side panels as indicated in Fig. 4 and pull the control panel.
When completely pulled out, the panel can rotate
45 downwards to facilitate the service operations on the internal parts.
3
2.5
1
Fig. 4
5
6
J
H
Open the drain tap I (Fig. 8) until the boiler is completely emptied.
Fig. 5
2.4
Fig. 8
2.6
Fig. 6
Diagrams
3.1
Wiring diagram for boiler equiped with full sequence ignition device type: ceza
Fan
Electrical
supply terminal
block
L
Air pressure
switch
COM
ignition
electrodes
gr
gr
M
~
m g/v c
g/v c
NO
g/v
gr
g/v
g/v
g/v
g/v
m
c
nn
gr n
g/v
c
n
gr
b
n
c
r
c
m
r r r
bc
b n
J11
n
gr
n
b
n
g/v
bc
COM
t
c
DHW temperature
probe NTC
1
n
NO
1
3
DHW flow CH temperature
Primary
probe NTC pressure switch
switch
r cn
~
g/vm c
Three way
diverter valve
r
n
b
v
~
Time switch
Pump
m --- brown
c --- blue
n --- black
b --- white
r --- red
gr--- grey
a --- orange
g --- yellow
g/v --- yellow/green
v --- green
Diagrams
3.2
Wiring diagram for boiler equiped with full sequence ignition device type: ceza
Fan
Electrical
supply terminal
block
L
Air pressure
switch
COM
ignition
electrodes
gr
gr
M
~
m g/v c
g/v c
NO
g/v
gr
g/v
g/v
g/v
g/v
m
c
nn
gr n
g/v
c
n
gr
b
c
m
b n
J11
n
gr
n
b
n
g/v
COM
NO
CH temperature
Primary
probe NTC pressure switch
g/vm c
r
n
b
v
~
Time switch
Pump
m --- brown
c --- blue
n --- black
b --- white
r --- red
gr--- grey
a --- orange
g --- yellow
g/v --- yellow/green
v --- green
Diagrams
Circuit voltages
3 way diverter
valve
Fan
230~
230~
230~
Eletric supply
terminal block
230~
Pump
Modulating
Gas valve
230~
230~
3.3
Safety
thermostat
--(5)
8.2
Diverter valve
D.h.w. circuit
C.h. circuit
11.2 13.5
14.2
NO TAG
15
16.2
Ignition electrode
D.h.w. filter
10.4
Detection electrode
9.9
7.2
Pump
--(3)
Defect
#
--(4)
Flue pipes
--(2)
17.2
Safety thermostat
--(9)
--(8)
Injectors
Components to check
Expansion vessel
Fault finding
---
---
Safety valve
Appliance operation
lamp green (1)
ON --- fast pu
ulses
OFF
OFF
ON
OFF
Pressure gauge
---
---
Appliance operation
lamp green (1)
ON ---- norm
mal pulsess
---
---
Noisy bolier
Incorrect modulation
C.h. circuit
11.2 13.5
D.h.w. filter
10
8
9
(10)
14.2
16.2
17.2
--(8)
Injectors
--(9)
Expansion vessel
---
---
A jammed by--- pass could cause the over--- heating of the main
circuit and the intervention of the safety thermostat.
Check the minimum gas pressure at the outlet test point of the
gas valve (see sect. 10.3) and compare it with the value given
on the installation booklet.
Verify the cleanness of injectors.
Check the pressurization of the expansion vessel. Refer to the
installation manual for proper values.
d.h.w. pressure too high or flow rate too high. If necessary insert a flow rate limiter (13.6).
NO TAG
15
Ignition electrode
10.4
Safety valve
Components to check
Detection electrode
9.9
Gas valve (modulating operator)
stop valves.
Check the gas pressure at the inlet test point of the gas valve
(see sect. 10.3) with the boiler at rest and during operation and
compare it with the values given on the installation booklet.
8.2
D.h.w. circuit
7.2
Note
OFF
F
--(5)
Pump
J
--(3)
Diverter valve
Defect
#
--(4)
Flue pipes
--(2)
Safety thermostat
Pressure gauge
5.1
Characteristics
C
G
B
A
E
D
Fig. 11
8
9
Fig. 9
I
H
Fig. 10
5.2
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Remove the combustion chamber lid B by unscrewing the screws C (Fig. 11).
3b
10
Fig. 12
5.3
Cleaning
6.1
Function
6.2
The d.h.w heat exchanger A in Fig. 13 allows the instantaneous transfer of heat from the primary hydraulic circuit to the water destined for d.h.w use.
Removal
Fig. 15
5
Fig. 13
Fig. 16
11
Pump
7.1
Function
n
Check that the impeller is integral with the rotor.
With the boiler off remove the front and right hand side
case panels, lower the control panel and empty the primary circuit.
Remove the pump head by undoing the screws which
hold it to the pump body and check that the impeller is
firmly joined to the rotor.
7.3
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Remove the front and right hand side case panels
Empty the primary circuit of the boiler.
Extract and lower the control panel.
Disconnect the connector B (Fig. 18).
Unscrew the connection C and move the pipe upwards freeing it from the outlet port of the pump.
Remove the fork D and the capillary pipe .
Remove the locking plate E right (Fig. 18).
1
2
3
4
5
6
7
C
B
D
Fig. 17
7.2
Checks
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
n
Check that the pump is not seized and that the
movement of the rotor is not subject to mechanical impediments.
E
Fig. 18
8
9
With the boiler off, remove the front panel. Remove the
air release plug of the pump and turn the rotor with a
screwdriver.
n
With the boiler off, remove the front panel and disconnect the connector B (Fig. 18).
H
F
I
Fig. 19
Reassemble the pump carrying out the removal operations in the reverse order. When reassembling the
pump, check the correct location of the O---ring gasket
in the inlet port of the pump that seals the connection
between the pump and the brass group .
8.1
Function
Spindle B
not visible
The diverter valve A (Fig. 20) has the function of modifying the hydraulic circuit of the boiler by means of an
electric command given by the electronic control p.c.b.
in order to send the water that exits the primary heat exchanger towards the c.h. system or towards the d.h.w.
heat exchanger.
9,4 Kohm
bn
0V
bu
bk
Open circuit
230 V
bn = brown
bu = blue
bk = black
Spindle B
visible
Open circuit
Checks
Check the electrical continuity
bn
bu
230 V
Fig. 20
8.2
9,4 Kohm
bk
bn = brown
bu = blue
bk = black
0V
8.3
1
2
3
13
Fig. 23
8.4
1
2
3
4
5
6
L
Fig. 25 Rear view of the boiler
10
F
H
Fig. 24
7
8
14
Fig. 26
11
9.1
Function
Inlet Information
On the Electronic
p.c.b.......
starting
control
Function control*
C.h. temperature adjustment*
D.h.w. temperature adjustment*
Function dip---switches
Max. c.h. gas pressure adjustment
Ignition gas pressure adjustment
Boiler reset button*
*control panel fascia
From other boiler devices....
C.h. temperature probe NTC
D.h.w. temperature probe NTC
D.h.w. flow switch
Primary circuit flow switch
Room thermostat (if fitted)
Time switch
Flame presence signal*
*from the full sequence ignition device
The fundamental function of the Electronic starting control p.c.b. is that of controlling the boiler in relation to the
external needs (i.e. heating the dwelling or heating the
water for d.h.w. use) and operating in order to keep the
temperature of the hydraulic circuits constant.
This is obviously possible within the useful power and
maximum working temperature limits foreseen.
Generally, the Electronic starting control p.c.b. receives
inlet information coming from the boiler (the sensors)
or from the outside (knobs, room thermostat, etc.), processes it and consequently acts with outlet commands
on other components of the boiler (Fig. 27).
9.2
On the Electronic starting control p.c.b. several selection, adjustment and protection devices are located.
(Fig. 28).
Some of these devices are directly accessible by the
user (function control, temperature adjustment potentiometers etc.) others are accessible by removing the
service panel or the control panel lid.
16
15
14
13
12
11
3
10
Fig. 28
Outlet command
Pump
Three way diverter valve
Full sequence ignition device
Modulation operator
Appliance operation light*
Operation/service lamps
Lock ---out signal lamp*
*control panel fascia
Fig. 27
1
2
3
4
5
6
7
8
9
10
11
13
Dip---switch selectors
14
Operation lamps
15
16
9.3
75 C
Fig. 30
9.4
Fig. 29
16
Operation lights
C.h. operation
Boiler ON condition
(function control in
position)
D.h.w. operation
or
D.h.w. operation
Excessive temperature on primary circuit
g
--- Lack of burner ignition
Service operation
or
), by moving and
With the boiler switched ON (
re---setting to its original position any of the function selectors 13 (Fig. 28), the Electronic starting control
p.c.b. goes into service operation mode and all the
lamps (14 in Fig. 28) are then activated.
To reset the Electronic starting control p.c.b. to the normal operation it is necessary to turn the knob
to the
position or switch off the boiler for a short while at
the fused spur isolation switch.
The following table gives the relationship between each
of the possible lamp combinations and their meaning.
Lamp
OFF
Lamp
ON
Flashing lamp,
alternate with
another lamp.
* These conditions are normal only for a short time when the
power supply is applied to the boiler.
If permanent they indicate a faulty p.c.b.
9.5
Dip---switch selectors
ON (1)
OFF (0)
13
Fig. 31
f
Selector 1
This forces the boiler to operate at the minimum gas
pressure in order to allow the adjustment of the minimum gas pressure at the burner (on the modulation operator of the gas valve).
17
Selector 2
Position of selector
Natural gas
On
120 mA
L.P.G.
Off
165 mA
Fig. 32
Selector 3
9.7
Normal
Selector 4
30 sec.
9.9
3 min.
Fig. 34
9.6
Setting jumpers
12 3456 789
18
Checks
Check that the fuse is complete
9.10
Fig. 35
n
OFF (0)
9.8
Fig. 33
12 3456 789
Fig. 36
Gain access to the parts located inside the control panel as explained in the section 2.3 of this
manual.
Remove all the wiring connected to the Electronic
starting control p.c.b..
A
A
Fig. 37
4
5
6
Attention
After installing the Electronic starting control p.c.b. :
10
) and d.h.w. (
) temMake sure the c.h. (
perature adjustment knobs can move freely for
the complete range.
If not, remove the spindle again as described at
step 3, turn the knob half a turn and re---insert the
spindle.
11
Fit the p.c.b. into the control panel by first inserting the front lower edge under the control knob
shafts. Lower the rear edge and ensure that no
wiring is trapped beneath.
Insert the spindles in the control panel knobs untill the notch A (Fig. 38) reaches the potentiometer edge. It is not necessary to force them in
the knob.
Fig. 38
Important
19
mode
Taking
water from the domestic hot
water circuit?
YES
(sec. 9.12)
Is primary circuit
temperature higher than that
selected?
NO
NO
YES
Circulator off
Operates motorised valve
Ignition device off
NO
YES
lock memorised?
YES
NO
cancels lock
NO
YES
starts fan
NO
YES
beginning of wait period
NO
NO
NO
end of ignition
period?
NO
presence of flame?
YES
NO
YES
YES
starts ignition discharges
opens gas valve
beginning of ignition period
flame presence?
YES
YES
closes gas valve
YES
flame presence?
NO
YES
Fig. 39
20
NO
NO
Safety thermostat
opens the circuit?
YES
mode
Switch in the
Taking
water from the domestic hot
water circuit?
YES
Circulator on
YES
function mode
Is domestic
hot water outlet temperature
lower than that
required?
NO
NO
YES
Circulator off
Ignition device off
lock memorised?
NO
cancels lock
NO
YES
starts fan
NO
YES
beginning of wait period
NO
NO
NO
end of ignition
period?
NO
presence of flame?
YES
NO
YES
YES
starts ignition discharges
opens gas valve
beginning of ignition period
flame presence?
YES
YES
closes gas valve
YES
flame presence?
NO
YES
NO
Safety thermostat
opens the circuit?
YES
NO
Fig. 40
21
10
10.1
Function
7
2
3
6
Fig. 42
10.3
Adjustment
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
5
Fig. 41
10.2
10
11
12
Modulation operator
On---off operators
22
10.4
10.6
Checks
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
n
1
2
n
1
2
3
Fig. 43
10.5
1
2
3
4
G
F
Fig. 45
Fig. 44
23
11
11.1
Function
11.2
Checks
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
n
1
2
3
Mechanical function
Remove the front panel of the case.
Start and stop the boiler either in d.h.w. or c.h.
mode.
Looking through the switch box verify the position
of the shaft B referring to Fig. 48.
Boiler OFF
Boiler ON
Fig. 48
A
I
Electrical check
Fig. 46
This hydraulic/membrane operated electrical micro--switch device will control the functioning of the ignition
control circuit, providing there is an adequate quantity
and flow of water in the primary circuit. Any failure of the
pump or obstructions in the primary circuit, whilst in
either c.h. or d.h.w. modes, will not allow the device to
operate.
This device is connected to the electronic control p.c.b.
and if, after the pump operates, it does not activate within 20 seconds the control board will indicate that a fault
condition (see section 9.4 of this manual) has occurred.
do not use
Fig. 49
11.3
C
D
n
1
2
3
Fig. 47
24
Removal
G
E
2
Fig. 50
12
12.1
Function
12.2
1
2
Fig. 52
Checks
Turn off the flow and return isolation valves and
empty the primary circuit of the boiler.
Remove the protective cap J (Fig. 51) from the
valve on the top of the expansion vessel and connect a suitable air pressure gauge.
12.4
1
2
J
3
4
Fig. 51
12.3
Fig. 53
25
13
13.1
The d.h.w. flow switch A in Fig. 54 is a device that generates an electrical signal when hot water is drawn.
13.2
1
2
3
4
5
6
7
8
9
10
1
A
3
4
5
Fig. 54
7
8
9
Fig. 56
13.3
Checks
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
n
1
2
13.4
Fig. 55
26
1
2
13.5
1
2
3
4
5
13.6
Flow limiter
If on the M90F.28S model the flow rate of the d.h.w. circuit is too high, it is possible to limit it by installing a flow
limiter. The following sizes are available:
Nominal flow rate (litres/min)
Colour
10
Yellow
12
Brown
Unscrew the threaded ring 7 (Fig. 56) and remove it from the body 2.
27
14
Temperature probe
14.2
14.1
Function
Temperature---resistance relationship
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Checks
14.3
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Refer to Fig. 59 for the c.h. Temperature probe
and to Fig. 60 for the d.h.w. Temperature probe.
2
3
4
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Fig. 57
A
Fig. 59
A
B
c.h.
return
Fig. 58
28
c.h.
flow
d.h.w.
inlet
d.h.w.
outlet
Fig. 60
15
By---pass valve
15.1
Function
15.2
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Unscrew the connector B and remove the by--pass valve C (Fig. 62).
Fig. 62
A
Fig. 61
29
16
16.2
16.1
Function
Checks
Check the position of the electrode edges
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
The third electrode is the detection electrode and it detects the presence of the flame.
Fig. 63 shows the electrodes configuration on the models M90F.24S, M90F.24SR, M90F.28S, M90F.28SR.
Detection
Ignition
Male
Female
Fig. 65
1
2
Fig. 63
16.3
Detection
Male
2
3
3b
4
Fig. 64
30
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
Ignition
1
Female
31
17
Safety thermostat
17.1
Function
17.3
Removal
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
1
1b
Consequently, the full sequence ignition device attempts to light the burner and, at the end, locks the
boiler and lights the lock ---out signal lamp.
B
Fig. 68
2
3
D
E
Fig. 67
17.2
Checks
Warning: isolate the boiler from the mains
electricity supply before removing any
covering or component.
n
1
2
n
1
2
32
Fig. 69
4
5
18
Description
173---148
173---149
169---069
169---070
3
4
E83---121
6
7
E83---129
169 127
E83---013
BI1193 500
KI1064 506
BI1202 102
1
1
1
1
1
1
BI1222 100
BI1366 102
BI1366 103
BI1376 105
BI1193 105
KI1267 103
BI1366 107
BI1376 104
BI1131 100
BI1172 103
BI1202 101
CIMM 6 litres
Watts
Orkly (alternative)
9
10
E83---178
E83---180
E83---181
11
E83---196
E83---197
12
13
E83---142
2
1
BI1326 100
BI1326 107
BI1326 108
BI1326 101
BI1366 109
1
1
BI1515 107
BI1305 101
1
1
BI1001 101
BI1001 102
1
1
1
1
1
1
1
1
1
BI1272 100
BI1011 505
BI1091 104
BI1011 103
BI1101 102
BI1172 105
BI1005 105
BI1001 117
BI1123 101
1
1
BI1193 102
BI1123 103
BI1193 103
14
E01---204
E01---205
15
16
17
18
19
20
21
22
23
E00---684
E83---082
E00---688
E83---086
E83---101
169---083
164---026
E83---127
24
E83---126
Elbi
ELTH --- type 261
33
E83---122
26
E83---145
Detection electrode
(mod. M90F.28S, M90F.28SR)
Detection electrode (mod. M90F.32S)
Temperature ---pressure gauge
BI1123 102
BI1193 104
BI1475 108
IMIT
6
5
9
10
12
13
11
14
20
34
21
15
16
22
17
23
19
18
24
25
26
*1796209187*
17962.0918.7 4006 44A4 UK